Training Videos Roll Forming Design
Lesson 1 - Defining a simple U profile

You learn how to define a simple U profile, symmetric and unsymmetrical, by using the Toolbox Profile Design. Then you learn to understand the structure of the profile list, the reference point, and the meaning of the different profile elements.

Lesson 2 - Defining a complicated profile

You learn how to import a complicated profile, symmetric and unsymmetrical, by using the Read CAD-Contour function. You learn how to detect a faulty CAD drawing and what to do in case of import errors.

Lesson 3 - Creating the flower pattern

You learn how to create the flower pattern for a simple U profile by manual specification of the bending sequence. You see how to consider the stress of band edge during design and what to do if the stress exceeds the yield stress of the material. Then you get to know the different bending methods: Constant developed length method, constant radius methods, track holding method and a method for compensating the spring back. At the end you see how to transfer the designer's know-how to a new project and how to create a flower pattern automatically.

Lesson 4 - Defining machine properties

You learn how a roll forming machine and a tube forming machine is defined in the machine window. The difference between forming stands and calibration stands is shown. You learn to to set-up the shaft and axles properties.

Lesson 5 - Creating rolls

You learn how to create rolls, first the very quick method by scanning the profile contour. For special needing it is necessary to define a roll contour that differs from the profile contour. It is shown how to create it in CAD and import it.

Lesson 6 - Verifying roll design by FEA

You learn how to verify the roll design by FEA - Finite Element Analysis. The FEA system LS-Dyna is a suitable instrument to check if the designed rolls are able to produce the desired profile with the requested allowances. The handling procedure is shown for the example bumper project.

Lesson 7 - Export CAD drawings and manufacturing data

You learn how to transfer drawings and 3D models to CAD. Export parts list and sawing list respectively for cutting the roll blanks from the bar is shown. You learn to know the three options to export milling data: G codes to the machine control, DXF files to a CAD/CAM system, and print output.

Lesson 8 - Designing shaped and round tubes

You learn how to use the automatic creation of calibration passes for shaped tubes that should be formed from from a round welded tube. Then you see the automatic development of a tube flower pattern and how to modify the passes manually. Afterwards the creation of roll tools for breakdown passes, fin passes and calibration stands is shown.

(Will be continued soon)

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